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Suzuki Ozark User Manual

Suzuki Ozark
374 pages
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GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
DRIVE TRAIN
4
FUEL SYSTEM
5
LUBRICATION SYSTEM
6
CHASSIS
7
ELECTRICAL SYSTEM
8
SERVICING INFORMATION
9
FOREWORD
This manual contains an introductory description on
the SUZUKI LT-F250 and procedures for its inspec-
tion, service, and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections as
a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.

Table of Contents

Questions and Answers:

Suzuki Ozark Specifications

General IconGeneral
BrandSuzuki
ModelOzark
CategoryOffroad Vehicle
LanguageEnglish

Summary

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Explains meanings of signal words WARNING, CAUTION, and NOTE.

GENERAL PRECAUTIONS

Lists essential safety precautions for service mechanics and the vehicle.

FUEL AND OIL RECOMMENDATION

Recommendations for fuel and oil types, viscosity, and specifications.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Recommended intervals for periodic service work to maintain peak performance.

PERIODIC MAINTENANCE CHART

Chart detailing maintenance items, intervals, and actions (Inspect, Clean, Lubricate, Tighten, Replace).

MAINTENANCE AND TUNE-UP PROCEDURES

Detailed servicing procedures for items listed in the periodic maintenance chart.

AIR CLEANER

Procedure for cleaning the air cleaner element every three months.

VALVE CLEARANCE

Procedure for checking and adjusting valve clearance when the engine is cold.

SPARK PLUG

Inspection, removal, and replacement procedures for the spark plug.

ENGINE

ENGINE REMOVAL AND INSTALLATION

Sequential steps for engine removal and reinstallation.

ENGINE DISASSEMBLY

Procedures for disassembling the engine's top and bottom sides.

ENGINE COMPONENTS INSPECTION AND SERVICING

Inspection and servicing procedures for cylinder head cover and related components.

ENGINE REASSEMBLY

Steps for reassembling the engine in the reverse order of disassembly.

DRIVE TRAIN

REAR DRIVE REMOVAL

Step-by-step procedure for removing the rear drive assembly.

REAR DRIVE DISASSEMBLY

Disassembly procedures for the rear drive gear case and its components.

REAR DRIVE REASSEMBLY

Reassembly steps for the rear drive components in reverse order of disassembly.

FUEL SYSTEM

CARBURETOR

Construction details of the carburetor, listing all its parts.

SPECIFICATIONS

Specifications for different model variations (E-03, E-17, E-33).

REMOVAL

Step-by-step instructions for removing the carburetor.

DISASSEMBLY

Procedures for disassembling the carburetor's main components.

CLEANING

Guidelines for cleaning carburetor jets and circuits using spray or dip cleaners.

REASSEMBLY

Procedures for reassembling the carburetor components in reverse order.

LUBRICATION SYSTEM

CHASSIS

FRONT BRAKE

Construction details of the front brake system, including components and torque values.

BRAKE PAD REPLACEMENT

Procedure for replacing the front brake pads as a set.

BRAKE FLUID REPLACEMENT

Steps for replacing the brake fluid and bleeding the system.

BRAKE CALIPER REASSEMBLY AND REMOUNTING

Steps for reassembling and remounting the brake caliper with new seals.

FRONT SUSPENSION

Construction details of the front suspension, including components and torque values.

STEERING

Construction details of the steering system, including components and torque values.

REAR BRAKE

Construction details of the rear brake system, including components and torque values.

REAR SUSPENSION

Construction details of the rear suspension, including shock absorber and swingarm.

REASSEMBLY AND REMOUNTING

Reassembling and remounting the rear swingarm and suspension components.

ELECTRICAL SYSTEM

BATTERY

Information about MF battery maintenance, charging safety, and replacement.

CHARGING SYSTEM

Troubleshooting guide for charging system issues like battery drain.

STARTER SYSTEM

Troubleshooting guide for starter motor issues, including checks for relay and voltage.

IGNITION SYSTEM

Troubleshooting guide for ignition system issues like no spark or poor spark.

SERVICING INFORMATION

TROUBLESHOOTING

Engine troubleshooting guide for common complaints like starting issues, noise, and power loss.

ENGINE TROUBLESHOOTING

Common engine problems, their symptoms, possible causes, and remedies.

WIRING DIAGRAM

Complete wiring diagram for the vehicle's electrical system.

TIGHTENING TORQUE

Torque specifications for engine components.

SERVICE DATA

Service data for valves and guides, including dimensions and clearances.

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